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The undercuts wouldnt be a big deal, The only place theres even a little bit of an undercut is the hands, and the chin. And the hands you can see they made them almost vertical lines from the back and fingers, so to avoid the problem of making a mold

It depends on how thick I make the mold. The face is done, im going to do a test pull or two. I have some ULTRA light foam ish style resin im going to try. should make for a real nice and quick and cheap face

I Don't mean to put a Damper on your parade, but this is more than Likely going to run you at minimum $500.00 and up. VashDstampede did a run on these a while back and they were AWESOME!!!! but he like others found this, well.. in all honesty to be much more of a pain then what it's worth. First, you have to buy the material, Which most who start this kind of project will ask for people to help by donating funds, That in itself is a slippery slope because you always run the risk of people paying up front and getting no product. Second, comes the issue of shipping: Overseas is a Nightmare, let alone stateside and Third: You've got to start off small then up the numbers, Start the List with 5 or 10 at best, I've seen these threads as many of you here have as well, time and time again, think "Bowjunkie " RPF and you'll know what I mean.

By no means am I trying to discourage you. I wanted to do a run of Side Panels and still do, but the Military comes first, So again think hard about what you're getting into, do but if you do, GOD SPEED. "Semper" C

Here's what your Product would look like if you do decide to pursue it.

Getting that Look is very hard even with a casting. The biggest problem is getting the finer details out of the face which VashDstampede did, but he can tell you it did take a coulple of times to get it right you've got the spacing between the mouth and teeth.

Exciting to see what you come up with. I just ordered the face cast myself, and I intend to attempt the rest on my own. Good to know that I will have others to bounce ideas off of for this project. I may not be able to begin for a month or so due to time restraints, but will post progress, once I start building. Good luck to you.

Getting that Look is very hard even with a casting. The biggest problem is getting the finer details out of the face which VashDstampede did, but he can tell you it did take a coulple of times to get it right you've got the spacing between the mouth and teeth.

Man, I cracked up laughing at how you moved the threepio to make him look at Han...too funny~! Love your setup, BTW.